Hobby Blocks Including Latently-Adhesive Surfaces

ABSTRACT

Described herein is a block set including a plurality of blocks having latently adhesive surfaces. Also described is a method of creating a bound structure from the individual blocks, including activating the adhesive of the latently adhesive surface of one or more of the blocks; and contacting an activated adhesive surface of the one or more blocks with another of said blocks, to bond the blocks together.

CROSS-REFERENCE TO RELATED APPLICATION

The benefit under 35 U.S.C. §119(e) of U.S. Provisional PatentApplication Ser. No. 61/185,093 filed Jun. 8, 2009, is hereby claimed,and the disclosure thereof is hereby incorporated herein by reference.

FIELD OF THE INVENTION

The invention generally relates to hobby-type blocks and specificallyrelates to a set of blocks that may be adhesively joined, for example tobuild structures and mosaics.

BACKGROUND

Toy or hobby block sets are used by children to construct simplestructures. Hobby blocks are also used by children and adults to buildlarge-scale complex structures, for example replicas of landmarkbuildings. Such structures can be time- and labor-intensive to build, soa method of permanently preserving blocks in a specific construction isdesirable. Currently, users rely on the interlocking properties of theblocks to keep structures joined, however blocks can still becomedisengaged and structures thus demolished. Alternatively, exogenousadhesive compounds, such as ordinary glue, are applied to the blocks tomore strongly adhere them to each other, but utilizing such adhesivescan be tedious, messy, and unsuitable for children.

SUMMARY OF THE INVENTION

One aspect of the disclosure is a block set including a plurality ofblocks having latently adhesive surfaces.

Another aspect is a method of creating a bound structure from theindividual blocks, including activating the adhesive of the latentlyadhesive surface of one or more of the blocks; and contacting anactivated adhesive surface of the one or more blocks with another ofsaid blocks, to bond the blocks together.

For the articles and methods described herein, preferred features, suchas components, compositional ranges thereof, substituents, conditions,and steps, can be selected from the various examples provided herein.

Further aspects and advantages will be apparent to those of ordinaryskill in the art from a review of the following detailed description,taken in conjunction with the drawings. While the blocks and methods aresusceptible of embodiments in various forms, the description hereafterincludes specific embodiments with the understanding that the disclosureis illustrative and is not intended to limit the invention to thespecific embodiments described herein.

BRIEF DESCRIPTION OF THE DRAWINGS

While the specification concludes with claims particularly pointing outand distinctly claiming the subject matter that is regarded as thepresent invention, it is believed that the invention will be more fullyunderstood from the following description taken in conjunction with theaccompanying drawings. Some of the figures may have been simplified bythe omission of selected elements for the purpose of more clearlyshowing other elements. Such omissions of elements in some figures arenot necessarily indicative of the presence or absence of particularelements in any of the exemplary embodiments, except as may beexplicitly delineated in the corresponding written description. None ofthe drawings are necessarily to scale.

FIG. 1 is a perspective view of one embodiment of a toy block.

FIG. 2 is a perspective view of the block shown in FIG. 1 with thebottom and rear plans indicated with dashed lines.

FIG. 3 is a top plan view of the block shown in FIG. 1

FIG. 4 is a bottom plan view of the block shown in FIG. 1

FIG. 5 is a side elevation view of two such blocks in an aligned state.

DETAILED DESCRIPTION

Described herein is a hobby block set including a plurality of blockshaving latently adhesive surfaces. Also described is a method ofcreating a bound structure from the individual blocks, includingactivating the adhesive of the latently adhesive surface of one or moreof the blocks; and contacting an activated adhesive surface of the oneor more blocks with another of said blocks, to bond the blocks together.

The blocks and method are contemplated to include embodiments includingany combination of one or more of the additional optional elements,features, and steps further described below (including those shown inthe figures), unless stated otherwise.

As used herein, the term “comprising” indicates the potential inclusionof other agents, elements, steps, or features, in addition to thosespecified.

The term “block” is used herein for convenience to refer to articlesaccording to the disclosure having latently adhesive surfaces, but isnot intended to limit the articles to ones which are block-shapedaccording to preferred embodiments. In the broadest concept, the shapes,sizes, colors, and textures of the blocks are not intended to belimiting. For example, in one embodiment the blocks will be rectilinear,e.g. typically block-shaped, although the blocks can have, in additionor in the alternative, curvilinear geometries. The plurality of blockscan be the same size and shape, or the blocks can have different sizesand shapes. For example, in one embodiment the blocks will havedifferent sizes and shapes and will be provided with compatibleinterlocking geometries. In another embodiment, the blocks will berelatively flat, and will have combinations of curved and flat edgeprofiles, such as jigsaw puzzle pieces, wherein the set of blocks can beassembled together by aligning the edges of the blocks, like a jigsawpuzzle.

The blocks can be joined together, for example to construct vertical orhorizontal structures. For example, in one embodiment, the blocks willhave compatible interlocking geometries on the top and bottom surfacesand can be stacked vertically. In another embodiment, the blocks willhave complementary projections and recesses on side surfaces and can bejoined laterally. In one embodiment, for example, the blocks can berelatively thin and have laterally-interlocking surface geometries, suchas a jigsaw puzzle. In another embodiment, blocks will have interlockingand aligning geometries on all surfaces and can be joined bothvertically and laterally.

As described above, the surfaces of the blocks include a latentlyadhesive material that can be activated to form adherent bonds. Thelatently adhesive surfaces can allow the blocks to be bonded without theneed for exogenous adhesive, although exogenous adhesive can alsooptionally be used. Preferably, prior to activation of the adhesivesurface, blocks can be repeatedly joined and disengaged. In oneembodiment, the latently adhesive material, and preferably the entireblocks, will be made from non-toxic materials suitable for use bychildren. Put another way, the ingredients used preferably will benon-toxic in the concentrations used.

In one embodiment, the latently adhesive material comprising the blocksurface will be thermoplastic and preferably also injection-moldable. Inone embodiment, the entire block will be injection molded from alatently-adhesive material, such as one described herein. In otherembodiments, the block can be formed by casting, by thermoforming, orany other suitable process, optionally including cutting steps (e.g.milling or other tooling).

A preferred embodiment of the surface composition includes awater-soluble polymer, more preferably one that can be dissolved in coldwater. For example, the polymer can include a polyvinyl alcohol, forexample in an amount in a range of 60% by weight or greater, based onthe total weight of the formulation (wt. %), for example 60 wt. % to 92wt. % or 80 wt. % to 92 wt. %. The polyvinyl alcohol polymer preferablyhas a degree of a hydrolysis in a range of 70% to 99%, preferably in arange of 88% to 98%. Preferably, the 4% solution viscosity of thepolyvinyl alcohol at 23° C. is in a range of about 5 cps to about 50cps, more preferably about 8 cps to 30 cps. For example, a coldwater-soluble polymer can include a PVOH having a 4% solution viscosityat 23° C. of about 8, and a degree of hydrolysis of about 88. A hotwater-soluble polymer can preferably have a blend of one or more lowviscosity, high degree of hydrolysis PVOH polymers as principal PVOHcomponents, and one or more high viscosity, low degree of hydrolysisPVOH polymers as secondary PVOH components.

Polymer formulations will preferably further include one or moreplasticizers. Suitable plasticizers include, but are not limited to,glycerin; low-molecular weight polyethylene glycol (e.g., having aliquid consistency, for example having and a molecular weight such as MW200, MW 300, and MW 600); monoacetin; triacetin; triethyl citrate;sorbitol; 1,3-butanediol; D-glucono-1,5-lactone; and, propylene glycol.The plasticizer permeates the polymer structure, disrupts intermolecularhydrogen bonding, and permanently lowers intermolecular attractions.Plasticizers are preferably included in an amount in a range of 5 wt. %to 25 wt. %, or 8 wt. % to 25 wt. %.

The polymer formulation may optionally include secondary additives suchas antifoams, extenders, extrusion aids, compounding aids,lubricants/release agents, surfactants, and anti-blocking agents, as isknown in the art. Suitable lubricants/release agents include, but arenot limited to, fatty acids and their salts, fatty alcohols, fattyesters, fatty amines, fatty amine acetates, fatty amides, andcombinations thereof. Preferred lubricants/release agents are fattyacids, fatty acid salts, and fatty amine acetates. Examples include, butare not limited to, calcium stearate, magnesium stearate, stearic acid,and stearamide.

Suitable fillers/extenders/antiblocking agents/detackifying agentsinclude, but are not limited to, starches, modified starches,hydroxyethylated starches, crosslinked polyvinylpyrrolidone, crosslinkedcellulose, microcrystalline cellulose, carboxymethylcellulose, silica,metallic oxides, calcium carbonate, talc, mica, clays, and combinationsof the foregoing.

A preferred plasticized, cold water soluble, PVOH-based, extrudablepolymer is sold under the trade name MONOPOL C100 by MonoSol, LLC(Merrillville, Ind., USA) and has the formulation properties (at 23° C.,50% rh) described below in Table 1.

TABLE 1 CHARACTERISTICS ENGLISH METRIC Melt Flow Index (ISO 1133, — 27g/10 min 190 C., 21.6 kg) Density — 1.28 g/cm³ Melting Point, DSC 365°F. 185° C. Tensile Strength at Yield 4,400 psi 30 MPa (ASTM D638)Elongation at Break 140% 140% (ASTM D638) Flexural Modulus 36,000 psi248 MPa (ASTM D790) Izod Impact Strength 13.7 ft-lbf/in 7.3 N-m/cm (ASTMD256) Durometer Hardness, 72 72 Shore D (ASTM D2240) VICAT SofteningPoint, 10N, 248° F. 120° C. 50° C./hr (ASTM D1525)

A preferred plasticized, hot water-soluble, PVOH-based, extrudablepolymer is sold under the trade name MONOPOL H700 by MonoSol, LLC(Merrillville, Ind., USA) and has the formulation properties (at 23° C.,50% rh) described below in Table 2.

TABLE 2 CHARACTERISTICS ENGLISH METRIC Melt Flow Index (ISO 1133, — 10g/10 min 220 C., 10 kg) Melting Point, DSC 410° F. 210° C. TensileStrength at Yield 5,300 psi 36 MPa (ASTM D638) Elongation at Break 150%150% (ASTM D638) Flexural Modulus 58,000 psi 400 MPa (ASTM D790) NotchedIzod Impact Strength 25.5 ft-lbf/in 13.6 N-m/cm (ASTM D256) DurometerHardness, Shore D 74 74 (ASTM D2240) VICAT Softening Point, 10N, 343° C.173° C. 50° C./hr (ASTM D1525)

Each block can be homogenous in composition, with the core and surfaceincluding the same latently adhesive material. The block core canalternatively include a non-adhesive compound or it can be hollow. Apreferred embodiment includes a homogenous composition, for example tofacilitate manufacturing utilizing injection molding.

The blocks can have smooth surfaces or the surfaces can be provided withfeatures for aligning and/or interlocking blocks to each other. Theblocks can also be provided with aligning and/or interlockinggeometries. For example, the block surfaces can contain projections,whereby one or more projections on a first block will align with thenon-recessed surface portions of a second block, and optionally willengage with (e.g., by frictional engagement) the non-recessed surfaceportions and/or surface projections on the second block (e.g., viafrictional engagement between side wall surfaces of the projections witheach other). The block surfaces also can include recesses, for examplerecesses that are complementary to projections on block surfaces, e.g.for contacting alignment and optionally frictional engagement betweenblocks.

Various examples of such block features and geometries are known in theart, including LEGO bricks (The LEGO Group, Billund, Denmark), MEGABLOKS bricks (MEGA brands, Inc., Montreal, Canada), and Best-Lock bricks(Best-Lock Construction Toys, England), all of which employstud-and-tube coupling system for frictional engagement between blocks.See, for example, Danish page 92683 C (Jan. 29, 1962), the disclosure ofwhich is incorporated herein by reference. Another example of suchblocks includes KRINKLES/BRISTLE BLOCKS (Battat Inc., Plattsburgh,N.Y.), which employs evenly-spaced rows and columns of bristle-shapedprojections, wherein the gaps formed by the projections areapproximately the same size as the projections, thereby providing forfrictional engagement when the bristle-shaped projections from a firstblock are pushed into the gaps of a second block. Another exampleincludes jigsaw puzzles, e.g. wherein the blocks are relatively thin andhave features intended for lateral alignment.

The figures herein illustrate one embodiment of blocks and blockfeatures designed for alignment and, optionally, interlocking. As shownin FIGS. 1 and 3, a plurality of cylindrical projections 2 on side 4 ofblock 10 are uniformly spaced and sized. As shown in FIGS. 2 and 4, aplurality of cylindrical recesses 12 on side 14 on a first block 10 aredimensioned to receive the projections 2 of a second block 10, forexample in adjacent engagement, creating a unit of two aligned blocks asillustrated in FIG. 5. The projections 2 and recesses 12 can be sizedfor frictional engagement, such that the blocks remain joined if a firstblock 10 (e.g., the top block in FIG. 5, as shown) is lifted off asecond block (e.g., the bottom block in FIG. 5, as shown). For example,the diameters of projections 2 can be slightly larger than the diametersof recesses 12, to provide for a press fit engagement. Consistent withthe disclosure herein, if the blocks, or at least the surfaces ofprojections 2, and preferably also the surface of side 4, include anactivated latently-adhesive material, then the blocks will also bebonded together, and preferably fused together.

Individual blocks may be joined into a bound structure using a methodincluding activating the latent adhesive surface of a block andcontacting blocks together. It is also conceived that a first blockhaving one or more latently-adhesive surfaces can be bound to one ormore blocks that do not have latently-adhesive surfaces. Structures ormosaics can be assembled from such blocks by ensuring that the adhesiveblocks are spaced between non-adhesive blocks.

Blocks can be utilized to compose structures including mosaics andthree-dimensional constructions. A preferred embodiment of activation isapplying water to dissolve a block surface comprised of a water-solublecompound. Water as a solvent is readily accessible, inexpensive, andnon-toxic, so it is appropriate for children to use. Other methodscontemplated for activating the latent adhesive are employing solventsother than water, heating the surface, abrading the surface, andapplying pressure to the surface. Blocks may be joined througharranging, aligning, or interlocking blocks to create contactingsurfaces.

The adhesive can be activated prior to contacting blocks or subsequentto assembling multi-block units. A preferred embodiment is to activatean adhesive surface prior to contacting blocks, to maximize the surfacearea of activated adhesive. For example, surface 4 of block 10 in FIG. 1is dampened with water and then interconnected with side 14 of a secondblock 10, such as shown in FIG. 5. Alternatively, water can be appliedto the junction of side 4 of the bottom block and side 14 of the topblock after the blocks are joined (e.g. at the side walls 15). Inanother embodiment, the surface of side 4 of a first block 10 isdampened with water, and the surface of side 14 of a second block 10 isalso dampened with water, and then the blocks are joined as describedabove. The water can be applied by a sponge, by misting, or by any othersuitable means.

Contacting activated surfaces of blocks together creates adherent bonds.The bond can be permanent, resulting in unbreakable structures, forexample if the surfaces of the blocks are solubilized, and then joined.The bond could be initially semi-permanent, allowing for adjustment ofblocks after activating the adhesive, and then permanent. The bond couldbe non-permanent, permitting the disengagement of blocks. A preferredembodiment is a permanent bond to allow for the creation of lastingstructures. In one embodiment, the degree of bonding between blocks canbe temperature dependent. In another embodiment, the degree of bondingbetween blocks can be pressure dependent. A preferred method includesactivation and fusion of adhesive surfaces at room temperature andatmospheric pressure.

The dimensions and values disclosed herein are not to be understood asbeing strictly limited to the exact numerical values recited. Instead,unless otherwise specified, each such dimension is intended to mean boththe recited value and a functionally equivalent range surrounding thatvalue. For example, a degree of hydrolysis disclosed as “88%” is alsointended to mean “about 88%.”

All documents cited herein are, in relevant part, incorporated herein byreference; the citation of any document is not to be construed as anadmission that it is prior art with respect to the present invention. Tothe extent that any meaning or definition of a term in this documentconflicts with any meaning or definition of the same term in a documentincorporated by reference, the meaning or definition assigned to thatterm in this document shall govern.

While particular embodiments of the present invention have beenillustrated and described, it would be obvious to those skilled in theart that various other changes and modifications can be made withoutdeparting from the spirit and scope of the invention. It is thereforeintended to cover in the appended claims all such changes andmodifications that are within the scope of this invention.

Throughout the specification, where compositions are described asincluding components or materials, it is contemplated that thecompositions can also consist essentially of, or consist of, anycombination of the recited components or materials, unless describedotherwise. The invention illustratively disclosed herein suitably may bepracticed in the absence of any element or step which is notspecifically disclosed herein.

The practice of a method disclosed herein, and individual steps thereof,can be performed manually and/or with the aid of or automation providedby electronic equipment. Although processes have been described withreference to particular embodiments, a person of ordinary skill in theart will readily appreciate that other ways of performing the actsassociated with the methods may be used. For example, the order ofvarious of the steps may be changed without departing from the scope orspirit of the method, unless described otherwise. In addition, some ofthe individual steps can be combined, omitted, or further subdividedinto additional steps.

Example

Two pairs of structures made of a water-soluble injection-moldablepolymer were tested for their fusing characteristics. The polymers weremade from polyvinyl alcohol. One pair of structures was made with a hotwater-soluble polymer, and one pair was made with a cold water-solublepolymer.

A damp sponge was used to wet the surface of one part from each pair tosolubilize the surface polymer and activate the latent adhesive. Thepart with the activated surface was aligned with its partner part madeof the same polymer so that the activated surface of one part contactedthe second part. The structure formed from parts made with a coldwater-soluble polymer fused in about 2 minutes at room temperature. Thestructure formed from parts made with a hot water-soluble polymer fusedin about 12 hours at room temperature. No heat was applied duringfusion.

1. A block set that may be used to form unbreakable structures andmosaics, comprising a plurality of blocks comprising latently adhesivesurfaces that can be activated to form permanent bonds without exogenousadhesive.
 2. The block set in accordance with claim 1, wherein thesurfaces of said blocks are smooth.
 3. The block set in accordance withclaim 1, wherein each of said blocks comprises one of or bothprojections and recesses on at least one surface of said blocks, theprojections and/or recesses disposed for contacting alignment of saidblocks with respect to each other.
 4. The block set in accordance withclaim 3, wherein said blocks comprise both surface projections andsurface recesses, and said surface projections and said surface recessesare sized for frictional engagement between each other, respectively. 5.The block set in accordance with claim 3, wherein said projectionscomplement in shape said recesses on adjacent blocks.
 6. The block setin accordance with claim 1, wherein said blocks can be repeatedly joinedand disengaged prior to activation of the latent adhesive.
 7. A blockset in accordance with claim 1, wherein the surfaces of the blockscomprise a water-soluble, injection-moldable polymer.
 8. The block setin accordance with claim 7, wherein the water-soluble polymer comprisesa polyvinyl alcohol.
 9. The block set in accordance with claim 8,wherein said compound further comprises a plasticizer.
 10. The block setin accordance with claim 7, wherein said polymer is soluble in coldwater.
 11. The block set in accordance with claim 1, wherein the blockshave a homogenous, injection-molded structure.
 12. The block set inaccordance with claim 1, wherein the core of each block is hollow.
 13. Amethod of creating a bound structure from individual blocks, comprising:providing a plurality of blocks comprising latently adhesive surfaces;activating the adhesive of a latently adhesive surface of one or more ofthe blocks; and contacting an activated adhesive surface of the one ormore blocks with another of said blocks, to permanently bond said blockstogether.
 14. The method in accordance with claim 13, wherein saidactivating comprises wetting the latently adhesive surface with water.15. The method in accordance with claim 14, comprising performing saidcontacting while the wetted surface is damp.
 16. The method inaccordance with claim 13, wherein said activating comprises solubilizingthe latently adhesive surface.
 17. The method in accordance with claim13, comprising activating a latently adhesive surface on each of two ofthe blocks, and contacting said activated surfaces with each other, topermanently bond said blocks together.
 18. The method in accordance withclaim 13, comprising activating said latently adhesive surface at roomtemperature.
 19. The block set in accordance with claim 3, wherein theblocks have a homogenous, injection-molded structure.
 20. The block setin accordance with claim 8, wherein said polyvinyl alcohol polymer issoluble in cold water.